That's the dark side of a face mill--they're power suckers DeLuxe. I've stalled my 2HP spindle on my IH with a Glacern RF45. For that reason, I got in the habit of setting the HP limit in my G-Wizard calculator to be about half what the machine will handle.
G-Wizard will automatically scale back the feeds and speeds to accomodate the available HP. The other thing about setting a relatively low limit is it reminds me to take extra care with the workholding if I'm going to try to pump 2HP out of it in order to avoid flying debris!
But the bad news is this motor is putting in a pretty weak showing. If I punch up the cut that almost stalls: 0.030 depth, 50% width of cut, I'm showing only about 0.15 HP or 360 watts.
Seems like that darned motor should be good for more!
I'm wonder if it has something to do with the low rpms. For aluminum with carbide inserts on a facemill, you should be able to go faster. G-Wizard would have you running 2200 rpm and 60 ipm in 6061 with that facemill. I know you said you'd dialed up HSS, but I was unclear whether the 17ipm/776 rpm numbers were what you actually ran when it stalled?
If you ran faster, then you got more than 360 watts. Let us know the actual speeds and feeds so I can recompute. I have my fingers crossed to run the bigger motor on my lathe. If it doesn't work out, I'll go back to my VFD ways.
Cheers,
BW
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